UNIT MAINTENANCE MANUAL FOR RECOVERY VEHICLE, HEAVY, …combatindex.com/store/tech_man/Sample/M88_hercules/... · Boom Fails To Operate Or Operates Roughly 0097 00..... Boom Creeps

This manual supercedes TM 9--2350--292--20--1 dated 1 October 2000.Distribution Statement A: Approved for public release; distribution is unlimited.

01 JANUARY 2002HEADQUARTERS, DEPARTMENT OF THE ARMY

HEADQUARTERS, U.S. MARINE CORPS

UNIT MAINTENANCE MANUAL

FOR

RECOVERY VEHICLE, HEAVY,FULL--TRACKED: M88A2(NSN 2350--01--390--4683)

(EIC: ACQ)

TECHNICAL MANUALVOLUME 1 OF 2

TM 9--2350--292--20--1MARINE CORPS TM 07769B--20/2--1

TM 9--2350--292--20--1

i

MARINE CORPS TM 07769B--20/2--1

HEADQUARTERSDEPARTMENT OF THE ARMY

U.S. MARINE CORPSWASHINGTON, D.C. 01 JANUARY 2002

TECHNICAL MANUAL

UNIT MAINTENANCE MANUAL

RECOVERY VEHICLE, HEAVY, FULL--TRACKED:M88A2NSN 2350--01--390--4683 (EIC: ACQ)

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures,please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical Publications),through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is http://aeps.ria.ar-my.mil. If you need a password, scroll down and click on ”ACCESS REQUEST FORM”. The DA Form 2028 is locatedin the ON--LINE FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this formon the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program.You may also mail, fax or email your letter, DA Form 2028, direct to: Technical Publication Information Office, TA-COM--RI, 1 Rock Island Arsenal, Rock Island, IL 61299--7630. The email address is [email protected]. The fax number is DSN 793--0726 or Commercial (309) 782--0726.

Marine Corps users submit NAVMC Form 10772 directly to: Commanding General, Marine Corps Logistics Base(Code 850), Albany GA 31704--5000.

A reply will be furnished directly to you

TABLE OF CONTENTSWP Sequence No.

WARNING SUMMARY

HOW TO USE THIS MANUAL

General Information 0001 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 1 -- DESCRIPTION AND THEORY OF OPERATIONEquipment Characteristics, Capabilities and Features 0002 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Location and Description of Major Components 0003 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Data 0004 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Theory of Operation 0005 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 2 -- TROUBLESHOOTINGIntroduction to Troubleshooting 0006 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quick Guide to Troubleshooting (System/Malfunction) Index 0007 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Overview And Diagrams (ONAN) 0008 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Unit Fails To Crank 0009 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fails To Keep Running 0010 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Distribution Statement A:-- Approved for public release; distribution is unlimited.

TM 9--2350--292--20--1

ii

TABLE OF CONTENTS -- CONTINUEDWP Sequence No.

CHAPTER 2 -- TROUBLESHOOTING--CONTINUEDAuxiliary Power Unit Engine Hard To Start In Cold Weather 0011 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel Solenoid Fails To Energize 0012 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BAT/GEN Gauge Reads in Yellow Or Lower Red With APU Running AndAPU GEN Switch ON 0013 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .APU Control Box High Air Temp Indicator Does Not Light 0014 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .APU Control Box Low Oil Pressure Indicator Does Not Light WhenAPU Oil Pressure Is Low 0015 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .APU Control Box Engine Oil Pressure Gauge Reads Zero With APU Engine Running 0016 00. . . . . . . . . . .

Auxiliary Power Unit Overview And Diagrams (HATZ) 0017 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fails To Crank 0018 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fails To Keep Running 0019 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Hard To Start In Cold Weather 0020 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel Solenoid Fails To Energize 0021 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BAT/GEN Gauge Reads in Yellow Or Lower Red With APU Running AndAPU GEN Switch ON 0022 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .APU Control Box High Air Temp Indicator Does Not Light 0023 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .APU Control Box Low Oil Pressure Indicator Does Not Light WhenAPU Oil Pressure Is Low 0024 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .APU Control Box Engine Oil Pressure Gauge Reads Zero With APU Engine Running 0025 00. . . . . . . . . . .Auxiliary Power Unit Hourmeter Does Not Work 0026 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit High Air Temperature Light Is Illuminated AndDoor Fan Is Not Running 0027 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit High Air Temperature Light Is Illuminated AndSump Fan Is Not Running 0028 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bilge Pump Overview And Diagrams 0029 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bilge Pump Fails To Operate 0030 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bilge Pump Light Fails To Operate. All Other Accessory Lights Operate 0031 00. . . . . . . . . . . . . . . . . . . . . .

Communications Overview And Diagrams 0032 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Communications System Fails To Operate 0033 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driver’s Controls Overview And Diagrams 0034 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Will Not Steer Or Will Only Steer In One Direction 0035 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brakes Do Not Stop Vehicle Effectively 0036 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Pump Motor Runs Continuously And Brake Pressure Does Not Reach950 PSI (Old Configuration) Or 1300 PSI (New Configuration with Brake Modulation) 0036 00. . . . . . . . . . .Brakes Drag On One Or Both Sides 0037 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Does Not Respond Properly To Throttle Controls 0038 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purge Pump Fails To Operate (Purge Pump Cannot Be Heard Operating When Turned On) 0039 00. . . . .

Engine Overview And Diagrams 0040 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Fails To Crank When Starter Switch Is Pressed 0041 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Cranks At Normal Speed But Will Not Start 0042 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Cranks But Will Not Start In Cold Weather 0043 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Cranks Slowly And Will Not Start 0044 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Fails To Shut Off When Fuel Shutoff Switch Is Activated 0045 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Fails To Shut Off When Manual Fuel Shutoff Handle Is Pulled 0046 00. . . . . . . . . . . . . . . . . . . . . . . . .Engine Has Low Stall RPM, Does Not Develop Full Power, And HasExcessive Smoke From One Or Both Banks Of Cylinders 0047 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Has Excessive White Smoke 0048 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Has Low Stall RPM And Does Not Develop Full Power, But Exhaust Smoke Is Normal 0049 00. . .Engine Runs Rough Or Misfires And/Or Knocks 0050 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Use Excessive Fuel 0051 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dust Detector System Operating. Powerplant Warning Lamp And Dust DetectorWarning Lamps ”ON” And Pressure Switch Plungers Are Visible 0052 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Has Low Power And Excessive Black Smoke 0053 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel/Water Separator Operates Improperly 0054 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM 9--2350--292--20--1

iii


CHAPTER 2 -- TROUBLESHOOTING--CONTINUEDLow (Or High) Engine Oil Pressure; Oil Temperature Is Normal 0055 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Uses Excessive Oil 0056 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Oil Temperature Is High 0057 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Oil Blows From Dipstick Tube 0058 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Starter Cranks When Master Switch Is Turned On Or EngineStarter Fails To Shut Off When Engine Is Running 0059 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Cranks In Any Gear 0041 00 Step D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Starts But Fails To Keep Running 0041 00 Step D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Spins But Does Not Engage (Replace Starter) 0240 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Starter Operates With Low Battery Voltage (Replace StarterLow Voltage Protection Module) 0241 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enhanced Diagnostics System Overview and Diagram 0060 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sport Cannot Communicate With 1553 Bus Card 0061 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sport Cannot Communicate With Remote Terminal Unit 0062 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The Non--Volatile Calibration Data Stored In Remote TerminalUnit Failed An Internal Consistency Check After Being Read 0063 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Failed To Read The Non--Volatile Calibration Data 0064 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .All Sensors Signals Are Below Range Or Open 0065 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .All Signals At Remote Terminal Unit Connector J1 Are Below Valid Range Or Open 0066 00. . . . . . . . . . . .All Signals At Remote Terminal Unit Connector J2 Are Below Valid Range Or Open 0067 00. . . . . . . . . . . .All Signals At Cable Assembly 4W504 Connector J1 Are Below Valid Range Or Open 0068 00. . . . . . . . . .All Signals At Remote Terminal Unit Connector J3 Are Below Valid Range Or Open 0069 00. . . . . . . . . . . .All Signals At Remote Terminal Unit Connector J5 Are Below Valid Range Or Open 0070 00. . . . . . . . . . . .Signal From Sensor Is Below Its Valid Range, Indicates Both Circuits Are Open, Is AboveIts Valid Range, Indicates Its Circuits Are Closed, Or Was Not Processed Correctly 0071 00. . . . . . . . . . . . .

Exhaust Smoke Generating System Overview And Diagrams 0072 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Fails To Make Smoke 0073 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Produces Poor Quality Smoke Or Insufficient Quantity Of Smoke 0074 00. . . . . . . . . . . . . . . . . . . . .Vehicle Produces Smoke When Exhaust Smoke Switches Are Off 0075 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Smoke Indicator Lights Fails To Operate 0076 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Particulate System Overview And Diagrams 0077 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lack Of Air At Facepieces 0078 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor Does Not Operate 0079 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M3 Heater (1, 2, Or 3) Fails To Operate Air Purifiers Operate Properly 0080 00. . . . . . . . . . . . . . . . . . . . . . . .Blower Fails To Operate 0078 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor Overheats (Inspect Purifier And Housing, Replace As Necessary) 0706 00. . . . . . . . . . . . . . . . . . . . . .

Generator System Overview And Diagrams 0081 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine BATT/GEN Gauge Reads In Yellow OrLower Red Region With Main Engine Running 0082 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine BATT/GEN Gauge Reads In Green ButEngine Accessories Fail To Operate 0083 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator Out Indicator Does Not Light When Generator Switch Is Placed In On Position 0084 00. . . . . . .Engine BATT/GEN Gauge Shows No Or Incorrect Reading 0085 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulics System Overview And Diagrams 0086 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Oil Constantly Overheats 0087 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Hydraulics System Fails To Operate 0088 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Slow Or No Hydraulic Component Operation With Hydraulic Selector Set In Main Position 0089 00. . . . . . .Slow Or No Hydraulic Component Operation With Hydraulic Selector Set In Auxiliary Position 0090 00. . .Main Winch Fails To Operate Or Fails To Develop Full Power 0091 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Creeps With Control In Neutral 0092 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Fails To Release 0093 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Fails To Hold Load 0094 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Level Winder Fails To Operate 0095 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM 9--2350--292--20--1

iv


CHAPTER 2 -- TROUBLESHOOTING--CONTINUEDAuxiliary Winch Fails To Operate Or Develop Full Power 0096 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boom Fails To Operate Or Operates Roughly 0097 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boom Creeps With Boom Control In Neutral 0098 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boom Stayline Cables Become Slack During Live Boom Operation OrBoom Can Be Stowed Without Activating The Boom Safety Valve Control Lever 0099 00. . . . . . . . . . . . . . .Hoist Winch Fails To Operate Or Develop Full Power 0100 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoist Winch Creeps With Control In Neutral 0101 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoist Winch Brake Fails To Hold A Load 0102 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spade Fails To Operate 0103 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spade Creeps With Spade Control Handle In Hold 0104 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spade Lock Fails To Release 0105 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Transfer Pump Fails To Operate 0106 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Impact Wrench Fails To Operate Or Develop Full Power 0107 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lights Overview And Diagrams 0108 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dome Light Fails To Operate 0109 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Passive Night Viewer Or Passive Night Viewer Indicator Fails To Operate 0110 00. . . . . . . . . . . . . . . . . . . . . .One Or Both Winch Lights Fail To Operate 0111 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixed Spotlight Fails To Operate 0112 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troublelight Fails To Operate 0113 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gauge Panel Lights Fails To Operate 0114 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Headlights Fails To Operate 0115 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stoplight Assemblies Fails To Operate 0116 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stoplights Fail To Operate 0117 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turn Signals Fail To Operate 0118 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blackout Stoplights Fails To Operate 0119 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blackout Marker Lights Fail To Operate 0120 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blackout Drive Lights Fail To Operate 0121 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Service Lights Fail To Operate 0122 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Emergency Flasher Light Fails To Operate 0123 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .When Activating Lamp Test Switch, Indicator Will Not Come On 0124 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Master Relay Overview And Diagrams 0125 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No Power When Master Switch Is Turned On 0126 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No Power At Slave Receptacle 0127 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring System Overview And Diagrams 0128 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Gauge Fails To Operate Properly 0129 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Oil Temperature Gauge Fails To Operate Properly 0130 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharger Dust Detector Indicator Light Fails To Operate 0131 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Time Totalizing Meter Fails To Operate 0132 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Oil Temperature Gauge Fails To Operate 0133 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Oil Pressure Gauge Fails To Operate 0134 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Filter Clogged Indicator Fails To Light When Filter Is Clogged 0135 00. . . . . . . . . . . . . . . . . . .Charge Filter (Return Filter) Clogged Light Stays On 0136 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Oil Low Level Warning Light Stays On. Hydraulic Reservoir Is Full 0137 00. . . . . . . . . . . . . . . . . .Transmission Oil Filter Clogged Indicator Stays On 0138 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personnel Heater Overview And Diagrams 0139 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel Heater Fails To Operate Properly 0140 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel Heater Fails To Ignite. (Heater Blower Operates Properly) 0141 00. . . . . . . . . . . . . . . . . . . . . . . . .Personnel Heater Fails to Keep Burning 0142 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel Heater Smokes 0140 00/0142 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Takeoff Electrical System Overview And Diagrams 0143 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PTO Clutch Does Not Engage. Indicator Is Not Lit And GovernorDoes Not Operate Properly 0144 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .High Temperature Indicator Fails To Light when PTO Clutch OilTemperature Is High. All Other Systems Operate Properly 0145 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM 9--2350--292--20--1

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CHAPTER 2 -- TROUBLESHOOTING--CONTINUEDRadio Interference Suppression System Overview And Diagrams 0146 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Excessive Interference, Main Engine And APU Not Running. Accessories On 0147 00. . . . . . . . . . . . . . . . .Excessive Interference With Main Engine Running And Vehicle Stationary 0148 00. . . . . . . . . . . . . . . . . . . .Excessive Interference With APU Running And APUGenerator Switch On. Main Engine Is Off And Vehicle Is Stationary 0149 00. . . . . . . . . . . . . . . . . . . . . . . . . .Excessive Interference When Vehicle Is Traveling 0150 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Smoke Grenade Launcher System Overview And Diagrams 0151 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grenade Launcher Fails To Operate Properly. Some Or All Tubes FailTo Operate. All Other Systems Operate Properly 0152 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tracks And Suspension Overview And Diagrams 0153 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Pulls To One Side 0154 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Sags To One Side 0155 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Rides Excessively Hard 0156 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Makes Thumping Noise During Travel 0157 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Overview And Diagrams 0158 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Steers But Will Not Drive In Any Range 0159 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Will Not Drive In Low Range 0159 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Will Not Drive In Intermediate Range 0159 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Will Not Drive In High Range 0159 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Will Drive Forward But Not In Reverse 0159 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Creeps In Neutral 0159 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Cannot Be Downshifted 0159 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Oil Temperature High 0160 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilating Blower Overview And Diagrams 0161 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ventilating Blower Fails To Operate. All Other Systems Operate Properly 0162 00. . . . . . . . . . . . . . . . . . . . .Ventilating Blower Will Not Operate At Full Speed 0163 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ventilating Blower Is Unusually Noisy 0164 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning System Overview And Diagrams 0165 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Warning Light Does Not Light When Master Switch Is On Or WhenMain Engine Oil Pressure Is Below Operating Level 0166 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Warning Light Does Not Light When Engine Oil Temperature Is High 0167 00. . . . . . . . . . . . . . . . . .System Warning Light Does Not Light When Transmission Oil Temperature Is High 0168 00. . . . . . . . . . . . .System Warning Light Does Not Light When PTO Clutch Oil TemperatureIs High. (High Temp Indicator Is Lit 0169 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Warning Light Does Not Light When Brake Pressure Is Low 0170 00. . . . . . . . . . . . . . . . . . . . . . . . . .System Warning Light Does Not Light When Main Winch Malfunctions 0171 00. . . . . . . . . . . . . . . . . . . . . . . .Warning Horn Does Not Sound When Engine Is Running And System Warning Light Is Lit 0172 00. . . . . .System Warning Light Does Not Go Out After Engine Is Started 0173 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Low Brake Pressure Warning Light Does Not Light When Brake Pressure Is Below 450 PSI 0174 00. . . . .Vehicle Horn Fails To Operate 0175 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Warning Indicator Will Not Come On When Activating Winch Test Switch 0176 00. . . . . . . . . . . . . .Low Brake Pressure Warning Light Comes On And Warning Horn Sounds 0177 00. . . . . . . . . . . . . . . . . . . .

Winch Electrical System Overview And Diagrams 0178 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Level Winder Malfunction Indicator Fails To Light When Level Winder Malfunctions 0179 00. . . . . . . . . . . . .Winch Drum Malfunction Indicator Fails To Light When Winch Drum Malfunctions 0180 00. . . . . . . . . . . . . .Payout Light Indicator Fails To Light When Less Than Four Warps OfWire Rope Are Left On Drum 0181 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Fails To Shut Down During A Malfunction 0182 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Fails To Shut Down When Winch Test Switch Is Held In Test Position 0183 00. . . . . . . . . . . . . .Main Winch Does Not Operate With The Override Switch Held In The Override Position 0184 00. . . . . . . .Main Winch Power Is Not Reduced When Override Switch Is In Override Position 0185 00. . . . . . . . . . . . . .Winch Drum Malfunction Indicator Lights, Winch Is Operating Properly 0180 00 Steps H--O. . . . . . . . . . . . .Winch Payout Limit Indicator Lights, Winch Is Operating Properly 0181 00 Steps H--N. . . . . . . . . . . . . . . . . .

TM 9--2350--292--20--1

vi


CHAPTER 3 -- GENERAL MAINTENANCE INSTRUCTIONSService Upon Receipt 0186 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance Checks And Services 0187 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 4 -- POWERPACK MAINTENANCEPowerpack Assembly Replacement 0188 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Ground Hop Kit And Ground Hop Air Filtration Kit 0189 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Shroud Seals Replacement 0190 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Air Intake Elbow Replacement 0191 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Mount Assembly Repair 0192 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Rear Mount And Base Assembly Repair 0193 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Fuel Line Quick Disconnects And Related Components Replacement 0194 00. . . . . . . . . . . . . . . . . .Engine Oil Sampling Valve Replacement 0195 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Oil Filters Replacement 0196 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Damper And Oil Filter Housing Related Parts Replacement 0197 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Oil Level Gauge Rod And Filler Tube Replacement 0198 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder Head Oil Drain Tubes Replacement 0199 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine oil Hose assemblies, Tube Assemblies, And Related Parts Replacement 0200 00. . . . . . . . . . . . . . .

CHAPTER 5 -- FUEL SYSTEM MAINTENANCEElectric Fuel Pump And Mount Assembly Repair 0201 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Transfer Pump Hose Assemblies And Fittings Replacement 0202 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Transfer Pump Replacement 0203 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Injector Tube Brackets Replacement 0204 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Injector Nozzle Return Hoses And Related Parts Replacement 0205 00. . . . . . . . . . . . . . . . . . . . . . . . . .Engine Fuel Pump Replacement 0206 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Backflow Valve And Related Parts Replacement 0207 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Air Cleaner Assembly Replacement 0208 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Cleaner Restriction Gauge And Hose Assembly Replacement 0209 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Cleaner Damper, Handle And Seals Replacement 0210 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Cleaner Air Duct Assembly And Retaining Rod Replacement 0211 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Cleaner Air Intake Hoses And Tube Assemblies Replacement 0212 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharger Dust Detector System Replacement 0213 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filler Tube And Strainer Assembly Replacement 0214 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Level Transmitter And Front Fuel Tank Drain Plug Replacement 0215 00. . . . . . . . . . . . . . . . . . . . . . . . .Manual Fuel Shut--off Control Assembly Replacement 0216 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Hose Assemblies, Fittings And Valves Replacement 0217 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Valve Control Rods And Handwheel Replacement 0218 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel/Water Separator Automatic Drain System And Harness E2CA128--006 Replacement 0219 00. . . . . . .Fuel/Water Separator Filters Repair 0220 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel/Water Separator Operation Tests 0221 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Primary Fuel Filter Repair 0222 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manifold Heater Fuel Filter And Solenoid Replacement 0223 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left Manifold Heater Assembly and Related Parts Replacement 0224 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Right Manifold Heater Assembly and Related Parts Replacement 0225 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .Accelerator Controls And Linkage Repair 0226 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alignment/Adjustment Of Accelerator Controls And Linkage 0227 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 6 -- EXHAUST SYSTEM MAINTENANCEEngine Exhaust Pipes And Insulation Covers Replacement 0228 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharger And Exhaust Manifold Covers Replacement 0229 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 7 -- COOLING SYSTEM MAINTENANCEHydraulic Oil Cooler and Related Parts Repair 0230 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine And Transmission Oil Cooler Replacement 0231 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 7 -- COOLING SYSTEM MAINTENANCE -- CONTINUEDEngine Top Housing Assembly And Mounting Bracket Replacement 0232 00. . . . . . . . . . . . . . . . . . . . . . . . . .Engine And Transmission Oil Cooler Access Covers And Frames Replacement 0233 00. . . . . . . . . . . . . . . .Baffle Screen Replacement 0234 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Cooling Fans And Housings Replacement 0235 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Generator Oil Cooling System Lines And Fittings Replacement 0236 00. . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 8 -- ELECTRICAL SYSTEM MAINTENANCEEngine Generator Replacement 0237 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Generator Cradle And Bracket Replacement 0238 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .APU Voltage Regulator, Main Engine Regulator, Lead Assembly 3W193And Related Components 0239 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Starter, Cradle And Related Components 0240 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Low Voltage Starter Protection Module Replacement 0241 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Switch Panel Assembly Repair 0242 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gauge Panel Assembly, Support And Wiring Harness 4W152 Repair 0243 00. . . . . . . . . . . . . . . . . . . . . . . . .PTO/Accessory Panel Repair 0244 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Control Panel Repair 0245 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Harness Bracket Replacement 0246 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .APU Control Box And APU Control Box Bracket Repair 0247 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel Heater Control Box Assembly Repair 0248 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .High Beam Indicator Assembly And Bracket Repair 0249 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Stop Light Switch And Extension Replacement 0250 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Level Wind Limit Switches Replacement 0251 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Neutral Safety Switch Replacement 0252 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flasher (Flashing Light) Assembly Replacement 0253 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STE--ICE Resistor Box And Bracket Replacement 0254 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Current Shunt Replacement 0255 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Positive Bus Bar Replacement 0256 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Negative Bus Bar Replacement 0257 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Bulkhead Connectors Replacement 0258 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Smoke Switch And Switch Plate Assembly Repair 0259 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlight Dimmer Switch Replacement (Old Configuration) 0260 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlight Dimmer Switch Replacement (New Configuration With Brake Modulation) 0261 00. . . . . . . . . . . .Rear Service Lights Toggle Switch And Identification Plate Replacement 0262 00. . . . . . . . . . . . . . . . . . . . . .Brake Relay, Circuit Breaker And Brake Relay Cover Replacement 0263 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Bilge Power Load Relay, Circuit Breaker And Mounting Plate Replacement 0264 00. . . . . . . . . . . . . . . . . . . .Passive Night Viewer Dummy Connector Replacement 0265 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Passive Night Viewer Switch And Indicator Assembly Repair 0266 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Directional Signal Control Switch And Bracket Replacement (Old Configuration) 0267 00. . . . . . . . . . . . . . .Directional Signal Control Switch, Dimmer Switch And Bracket Replacement(New Configuration With Brake Modulation) 0268 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flasher (Directional Signal Control) And Mounting Plate Assembly Replacement 0269 00. . . . . . . . . . . . . . .Master Power Circuit Breaker Replacement 0270 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Master Relay, Mounting Bracket And Cover Replacement 0271 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Antenna Base Access Cover Replacement 0272 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlight Assembly Repair 0273 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlight Base Assembly 4W159 Repair 0274 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlight Sealed--Beam, Marker Assembly And Incandescent Lamps Replacement 0275 00. . . . . . . . . . . .Right And Left Rear Stop Lights And Stayline Cylinder Access Covers Repair 0276 00. . . . . . . . . . . . . . . . .Emergency Flasher Lamp assembly Repair 0277 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turn Signal Lamp Assembly Repair 0278 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Service Light Repair 0279 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Trouble Light Assembly Repair 0280 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spotlight Repair 0281 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 8 -- ELECTRICAL SYSTEM MAINTENANCE -- CONTINUEDWinch Illumination Lamp Assembly Repair 0282 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dome Light Assembly Repair 0283 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Oil Pressure, Low Oil Pressure And Temperature Sending Units And HighTemperature Switch Replacement 0284 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharger Pressure Transducer DCA Replacement 0285 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warning Horn, Warning Horn Relay, Automotive Horn And LeadAssemblies 4W156 Replacement 0286 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Proximity Switch Replacement 0287 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery, Battery Tray And Battery Terminal Replacement 0288 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Tray Cleaning Tubes Replacement 0289 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness And Cable Repair 0290 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 2W601 Replacement (Old Configuration) 0291 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 2W601 Replacement (Override Modification) 0291 01. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 2W602 Replacement 0292 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 2W612 Replacement (Override Modification) 0292 01. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W132 Replacement 0293 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W142 Replacement 0294 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W143 Replacement 0295 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lead Assembly 3W174 Replacement 0296 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W180 Replacement 0297 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W200 Replacement 0298 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W201 Replacement 0299 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W202 Replacement 0300 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W203 Replacement 0301 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W206 Replacement 0302 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W207 Replacement 0303 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lead Assembly 3W209 Replacement 0304 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lead Assembly 3W210 Replacement 0305 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lead Assembly 3W212 Replacement 0306 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Slave Receptacle Wiring Harness 3W213 And Wiring Harness 3W214 Replacement 0307 00. . . . . . . . . . .Lead Assembly 3W215 Replacement 0308 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W217 Replacement 0309 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lead Assembly 3W218 Replacement 0310 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W702 Replacement 0311 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W710 Replacement 0312 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W801 Replacement 0313 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W100 Replacement 0314 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W101 Replacement 0315 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W103 Replacement 0316 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W105 Replacement 0317 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W106 Replacement 0318 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W107 Replacement 0319 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W110 Replacement 0320 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W115 Replacement 0321 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W116 Replacement 0322 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W124 Replacement 0323 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W127 Replacement 0324 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W136 Replacement 0325 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lead Assembly 4W140 Replacement 0326 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W153 Replacement 0327 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W155 Replacement 0328 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lead Assembly 4W158 Replacement 0329 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W617 Replacement 0330 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W618 Replacement 0331 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W700 Replacement 0332 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 8 -- ELECTRICAL SYSTEM MAINTENANCE -- CONTINUEDWiring Harness 4W800 Replacement 0333 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Disconnect Bracket Replacement 0334 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Cable Clamps Replacement 0335 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ground Lead MS25083--7BC6 Replacement 0336 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Shutoff Wiring Harness Replacement 0337 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Fuel Tank Ground Strap Replacement 0338 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Right Fuel Tank Ground Strap Replacement 0339 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left Fuel Tank Ground Strap Replacement 0340 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator Ground Strap Replacement 0341 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Ground Strap Replacement 0342 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness Guard Replacement 0343 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ventilator Blower Assembly Replacement 0344 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VOLUME 2

CHAPTER 9 -- TRANSMISSION MAINTENANCETransmission Oil Cooler Lines Replacement 0345 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Oil Sampling Valve Replacement 0346 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Bracket Assembly Repair 0347 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Oil Temperature Transmitter Replacement 0348 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Oil Temperature Switch And Oil Pressure Transmitter Replacement 0349 00. . . . . . . . . . . . . .Transmission Control Assembly Replacement 0350 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Oil Breather, Transmission Oil Breather Tube, Hose, Fittings And OilPressure Transmitter Fittings Replacement 0351 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Filter Switch Replacement 0352 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Oil Filters Repair 0353 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 10 -- FINAL DRIVES MAINTENANCEOutput Reduction Unit (Output Drive) Replacement 0354 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 11 -- BRAKES MAINTENANCEBrake Linkage Alignment, Adjustment And Bleeding (Old Configuration) 0355 00. . . . . . . . . . . . . . . . . . . . . .Brake Linkage Alignment, Adjustment And Bleeding (New Configuration) 0356 00. . . . . . . . . . . . . . . . . . . . .Brake Linkage Alignment, Adjustment And Bleeding (New Configuration With Brake Modulation) 0357 00.Neutral Safety Switch, Steering Control Lock And Brake Lock Adjustment (Old Configuration) 0358 00. . .Neutral Safety Switch, Steering Control Lock And Brake Lock Adjustment (New Configuration)With Brake Modulation) 0359 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Brake Hose Assembly Replacement (Old Configuration) 0360 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Brake Hose Assembly, Bleed Valve Manifold And AssociatedParts Replacement (New Configuration) 0361 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Brake Hose Assembly, Bleed Valve Manifold And AssociatedParts Replacement (New Configuration With Brake Modulation) 0362 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Rod Assembly 12366874 Repair (Old Configuration) 0363 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Rod Assembly 12366874 Repair (New Configuration With Brake Modulation) 0364 00. . . . . . . . . . . .Brake Rod Assemblies 12364827--2 Repair 0365 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Shaft Assembly 12364824 And Brake Pedal ReturnSpring Replacement (Old Configuration) 0366 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Shaft Assembly 12364824 And Brake Pedal ReturnSpring Replacement (New Configuration With Brake Modulation) 0367 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Shafts 12364630 And 12364780 Replacement 0368 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Cable Replacement 0369 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Ball Joint Assembly Replacement 0369 01. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Hydraulic Cylinder Replacement (Old Configuration) 0370 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Hydraulic Cylinder Replacement (New Configuration With Brake Modulation) 0371 00. . . . . . . . . . . .

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TABLE OF CONTENTS -- CONTINUED

VOLUME 2--CONTINUEDWP Sequence No.

CHAPTER 11 -- BRAKES MAINTENANCE -- CONTINUEDBrake Accumulator Replacement 0372 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Charging Brake Accumulator 0373 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Boost Manifold And Modulating Valve Plate Repair (Old Configuration) 0374 00. . . . . . . . . . . . . . . . .Power Boost Manifold And Plate Repair (New Configuration With Brake Modulation) 0375 00. . . . . . . . . . .Brake Modulating Valve Assembly Repair (Old Configuration) 0376 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Modulating Valve Assembly And Brake PedalRepair (New Configuration With Brake Modulation) 0377 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Power Boost Hydraulic Manifold Repair (Old Configuration) 0378 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Power Boost Hydraulic Manifold Repair (New Configuration) 0379 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Power Boost Hydraulic Manifold Repair (New Configuration With Brake Modulation) 0380 00. . . . . .Service Brake Pump And Motor Assembly Replacement 0381 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Pedal And Bracket Assembly Repair (Old Configuration) 0382 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Lever And Bracket Assembly Repair (New Configuration With Brake Modulation) 0383 00. . . . . . . . .Brake Actuating Link Replacement 0384 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 12 -- WHEELS AND TRACKS MAINTENANCEIdler Arm Support Housing Lubrication Fittings, Relief Valves And Bushings Replacement 0385 00. . . . . . .Solid Rubber Wheels Replacement 0386 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Suspension Hub Assembly Repair 0387 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Suspension Arm Assembly Repair 0388 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torsion Bars And Torsion Bar Anchors Replacement 0389 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pivot Arm Assembly Repair 0390 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Track Support Roller Repair 0391 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Link And Components Repair (Old Configuration) 0392 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Link And Components Repair (New Configuration) 0393 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Idler Hub Assembly Repair 0394 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Idler Arm Assembly Repair 0395 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Idler Arm Housing Packing And Seal Replacement 0396 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Final Drive Hub And Sprocket Replacement 0397 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Track Shoe Assembly Replacement 0398 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Track Assembly Replacement 0399 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Track Binder Retainers Replacement 0400 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 13 -- STEERING AND SHIFTING CONTROL COMPONENTS MAINTENANCESteering Control Assembly Repair 0401 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Control Locking Rod Assembly Repair 0402 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Control Linkage (Crew Compartment) Repair 0403 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Control Linkage (Engine Compartment) Repair 0404 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Control Linkages Adjustment 0405 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shifting Control Linkage (Crew Compartment) Repair 0406 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shifting Control Linkage (Engine Compartment) Repair 0407 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shifting Control Linkages Adjustment 0408 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steer And Shifting Linkage Lubrication Adapter Fitting, Hoses And Hardware Replacement 0409 00. . . . . .

CHAPTER 14 -- TOWING ATTACHMENTS MAINTENANCETowing Pintle And Mount Repair 0410 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 15 -- SHOCK ABSORBERS MAINTENANCELockout Block Spacers And Bumper Assemblies Replacement 0411 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shock Absorber And Mounting Brackets Repair 0412 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 16 -- BODY, HOOD AND HULL MAINTENANCEAPU Cover Assembly Replacement 0413 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Auxiliary Housing Replacement 0414 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Deck Grilles And Engine Deck Access Doors Replacement 0415 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Guide Bar Mending Plate Replacement 0416 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Deck Assembly Replacement 0417 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stayline Tree Tray And Hook Block Retainer Replacement 0418 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Deep Water Fording Exhaust Plate Replacement 0419 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Deflector Assembly Repair 0420 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Exhaust Deflector Door Replacement 0421 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Deck Door And Torsion Bar Repair 0422 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Deck Cover Assembly Repair 0423 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Center Exhaust Door And Hold--Open Latch Replacement 0424 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Deck Base Assembly Repair 0425 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Access Door And Door Handle Replacement 0426 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoist Boom Rest And Latch Assembly Repair 0427 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoist Winch Cable Access Door And Seal Replacement 0428 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left Stowage Door Assembly Repair 0429 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel Door Locking Pin Assembly Replacement 0430 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left Personnel Door Assembly And Torsion Bar Repair 0431 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Right Personnel Door Assembly And Torsion Bar Repair 0432 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Compartment Rear Access Cover Replacement 0433 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hull Engine Compartment Access Covers Replacement 0434 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Tank Fill Access Cover Replacement 0435 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Cleaner Air Inlet Cover Replacement 0436 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Door Assembly Repair 0437 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .APU Door Assembly And Hold--Open Latch Repair 0438 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Door, Fan Assembly And Hold--Open Latch Replacement (HATZ) 0439 00. . . . . . . . . .Acetylene Access Port Armor Replacement 0440 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Bulkhead Access Plate Replacement 0441 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Armor Skirt Panel Hinge, Standoff And Stop Replacement 0442 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fender Replacement 0443 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Commander’s Cupola Repair 0444 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Commander’s Cupola Door assembly Repair 0445 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Driver’s Passive Night Viewer Mount Assembly Repair 0446 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Driver’s Cab Top Door Assembly Repair 0447 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel And Mechanic’s Cab Top Door Assembly 0448 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Driver’s Personnel And Mechanic’s Hatch Cushioning Pad Replacement 0449 00. . . . . . . . . . . . . . . . . . . . . .Direct Vision Block Replacement 0450 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Periscope Mounting Hardware Replacement 0451 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drain Valves, Controls And related Parts Replacement 0452 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drain Covers And Gasket Replacement 0453 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Subfloor Replacement 0454 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Floor Plate Assembly 12477573 Repair 0455 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Floor Plate Assembly 12477598 Repair 0456 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Commander’s And Personnel Seat Repair 0457 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Commander’s Sub--Base Assembly Repair 0458 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Commander’s Pedestal Repair 0459 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel Seat Assembly Repair 0460 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Driver’s And Mechanic’s Seat Repair 0461 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Driver’s And Mechanic’s Seat Shoulder Harness Replacement 0462 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 16 -- BODY, HOOD AND HULL MAINTENANCE -- CONTINUEDStowage Rack Assembly And Bracket Replacement 0463 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Retaining Straps Assembly, Acetylene Compartment DoorHardware And Associated Parts Repair 0464 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interior Stowage Baskets And Supports Replacement 0465 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid Container Bracket Assemblies Replacement 0466 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand Grenade Boxes Replacement 0467 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Passive Night Viewer Stowage Box Assembly And Mounting Bracket Replacement 0468 00. . . . . . . . . . . . .Binoculars Webbing Straps Replacement 0469 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Straps (Interior) Replacement 0470 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Straps (Exterior) Replacement 0471 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Portable Fire Extinguisher Brackets And Right Side Gas Particulate FilterBracket Support Replacement 0472 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left Side Gas Particulate Filter And Fire Extinguisher Bracket Support Replacement 0473 00. . . . . . . . . . . .Liquid Container Bracket Replacement 0474 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tool Box Assembly Replacement 0475 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Side Tow Bar Bracket Assembly Repair 0476 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tarpaulin Stowage Tray Replacement 0477 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ammunition Stowage Box Assembly, Oddment Tray Shelf And Support Replacement 0478 00. . . . . . . . . . .Flasher Lamp Case Replacement 0479 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicular Tool Box Rack, Oddment Tray Assembly And Bracket Replacement 0480 00. . . . . . . . . . . . . . . . .Ceiling And Bulkhead Rifle Clips Replacement 0481 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pioneer Tool Set Bracket Assembly Replacement 0482 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vise And Vise Adapter Replacement 0483 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare Tracks Stowage Clamps Replacement 0484 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare Drive Sprocket, Spare Road Wheel, Spare Support Roller And MountingBracket Replacement 0485 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Tow Bar Bracket Assembly Repair 0486 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lifting Chain Clamps Replacement 0487 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oxygen Tank Retaining Straps And Guard Replacement 0488 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140--Ton Snatch Block Support And Base Plate Assembly Repair 0489 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .Tow Cable Retainers, Clamps And Brackets Replacement 0490 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlight Stowage Base Assembly Replacement 0491 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Boom, Pad And Bracket Replacement 0492 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 17-- WINCHES, SPADE AND HOIST BOOM MAINTENANCEHoist Winch Wire Rope Assembly Replacement 0493 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoist Winch Wire Rope Roller And Bearing Housing Assembly Replacement 0494 00. . . . . . . . . . . . . . . . . .Hoist Winch Wire Rope Shield Replacement 0495 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoist Winch Hose Assemblies, Fittings, Adapters And Manifolds Replacement 0496 00. . . . . . . . . . . . . . . . .Main Winch And Spade Assembly Replacement 0497 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Ground Hop Kit 0498 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main winch Wire Rope Assembly Replacement 0499 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch And Spade Quick--Disconnect Couplings And Adapters Replacement 0500 00. . . . . . . . . . . . .Payout And Layer Limit Switches Replacement 0501 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Payout Limit Switch Adjustment 0502 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Layer Limit Switches Adjustment 0503 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diamond Screw Centering Adjustment 0504 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Drum And Diamond Screw Synchronization Adjustment 0505 00. . . . . . . . . . . . . . . . . . . . . . . . .Main Winch And Cable Guide Synchronization Adjustment 0506 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Level Winder Guard Replacement 0507 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 17-- WINCHES, SPADE AND HOIST BOOM MAINTENANCE -- CONTINUEDRoller Bracket Assembly Repair 0508 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Level Wind Limit Switches Adjustment 0509 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spade Assembly Lubrication Hoses, Tubes, Fittings And AdapterBlock Replacement 0510 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Cable Armor Plates And Guides Replacement 0511 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spade Upper And Lower stops Replacement 0512 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Winch Assembly, Plate And Cover Replacement 0513 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Winch Hoses And Fittings Replacement 0514 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Winch Wire Rope Assembly 0515 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Winch Hydraulic Motor And Flange Replacement 0516 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Winch Spooling Roller Assembly Repair 0517 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Winch Roller Bracket Assembly Repair 0518 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Control Valve Manifold Shields And Spade Control ValveRod And Handle Replacement 0519 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Control Valve Panel Instruction Plate Replacement 0520 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spade Lock Assembly Replacement 0521 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spade Assembly Repair 0522 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tackle Block Tray Replacement 0523 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoist Boom Pulleys Replacement 0524 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stayline Tree Chain Assembly Replacement 0525 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hull Drain Hose And Boom Foot Boot Drain Hoses Replacement 0526 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .Stayline Tree Wire Rope Assembly Replacement 0527 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoist Boom Stayline Tree Replacement 0528 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 18 -- BODY, CHASSIS OR HULL ACCESSORY ITEMS MAINTENANCEPersonnel Heater Assembly Replacement 0529 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Duct Hose And Plenum Drain Hose Replacement 0530 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel Heater Air Inlet Cover And Inlet Screen Replacement 0531 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel Heater Exhaust Hose/Tube Assembly And Insulation Blanket Replacement 0532 00. . . . . . . . . .Personnel Heater Fuel Pump Replacement 0533 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personnel Heater Fuel Filter Replacement 0534 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Decal Replacement 0535 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stencil Locations 0536 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Control Valve Data Plate Replacement 0537 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle Identification, Carc Painted And Shipping Data Plate 0538 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defuel Compartment Data Plate Replacement 0539 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spade Release Data Plate Replacement 0540 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Tank Filler Access Cover Data Plate Replacement 0541 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Door Data Plate Replacement 0542 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Connection Diagram Data Plate Replacement 0543 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 19 -- HYDRAULIC SYSTEM MAINTENANCEPower Take--Off (PTO) Shaft Replacement 0544 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Hydraulic Pumps’ Assembly And Power Take--Off (PTO) Clutch Replacement 0545 00. . . . . . . . . . . .Fuel Transfer Pump Motor And Pump Base Replacement 0546 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Hydraulic Pump Repair 0547 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Hydraulic Pump Repair (HATZ) 0548 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Safety Valves Replacement 0549 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Filter Manifold Assembly Repair 0550 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Filter Manifold Check Valve And Pressure Sensing Valve Replacement 0551 00. . . . . . . . . . . . . .Hydraulic Filter Manifold Adjustable Relief Valve Replacement 0552 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Filter Manifold Return Circuit Or Charge Circuit Indicator Switch Replacement 0553 00. . . . . . . .

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CHAPTER 19 -- HYDRAULIC SYSTEM MAINTENANCE -- CONTINUEDHydraulic Oil Filters Replacement 0554 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flow Regulating Valve And Fittings Replacement 0555 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main/Hoist Winch Directional Control Valve Assembly Replacement 0556 00. . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Power Reduction Manifold Assembly And Brackets Replacement 0557 00. . . . . . . . . . . . . . . . .Spade Release Valve and Bracket Replacement 0558 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boom Shut--Off Valve Assembly Repair 0559 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cross Port Relief/Anticavitation Manifold Repair 0560 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Control Valves Handle Replacement 0561 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Control Valves Replacement 0562 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boom Limit Valve Adjustment 0563 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .APU Pressure Switch Replacement 0564 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Pump Hydraulic Lines And Fittings Replacement 0565 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Transfer Pump Motor And Stayline Cylinder Hydraulic Lines And Fittings Replacement 0566 00. . . . .Main Winch Safety Valve Hydraulic Lines And Fittings Replacement 0567 00. . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Filter Manifold Hydraulic Lines And Fittings Replacement 0568 00. . . . . . . . . . . . . . . . . . . . . . . . . .Manual Control Valve And Fittings Replacement 0569 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defuel Compartment Hydraulic Quick--Disconnect Coupling And Elbow Replacement 0570 00. . . . . . . . . . .Flow Regulating Valve Hydraulic Lines And Fittings Replacement 0571 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .Main And Hoist Winch Directional Control Valve HydraulicLines And Fittings Replacement (Old Configuration) 0572 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main And Hoist Winch Directional Control Valve HydraulicLines And Fittings Replacement (New Configuration) 0573 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch Power Reduction Manifold Hydraulic Lines And Fittings Replacement 0574 00. . . . . . . . . . . . . .Spade Release Hydraulic Lines And Fittings Replacement 0575 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Boom Shutoff And Cross Port Relief/Anticavitation Manifold HydraulicLines And Fittings Replacement 0576 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Control Valve Manifold Assembly Hydraulic Lines And Fittings Replacement 0577 00. . . . . . . . . .Boom Limit Valve Hydraulic Lines And Fittings Replacement 0578 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoist Winch Hydraulic Lines And Fittings Replacement 0579 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoist Boom Actuating Cylinder Hydraulic Lines And Fittings Replacement 0580 00. . . . . . . . . . . . . . . . . . . . .APU And APU Pressure Switch Hydraulic Lines And Fittings Replacement 0581 00. . . . . . . . . . . . . . . . . . . .APU And APU Pressure Switch Hydraulic Lines And Fittings Replacement (HATZ) 0582 00. . . . . . . . . . . . .Hydraulic Reservoir Hydraulic Lines And Fittings Replacement 0583 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Reservoir Hydraulic Lines And Fittings Replacement (New Configuration) 0583 01. . . . . . . . . . . .Hydraulic Hose Retainer And Retaining Covers Replacement 0584 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Connection Panel Replacement 0585 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 20 -- AUXILIARY GENERATOR AND ENGINE AND CONTROLS (APU) MAINTENANCEAuxiliary Power Unit Assembly Replacement 0586 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Assembly Replacement (HATZ) 0587 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit (APU) Ground Hop Kit 0588 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit (APU) Ground Hop Kit (HATZ) 0589 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Support Replacement 0590 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Support, Data Plate, Decal And Door FanAir Scoop Replacement (HATZ) 0591 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Wiring Harness Cable Clamps Replacement 0592 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Identification Plate And Decal Replacement 0593 00. . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Identification Plate And Decal Replacement (HATZ) 0594 00. . . . . . . . . . . . . . .Auxiliary Power Unit Throttle Adjustment Linkage Replacement (HATZ) 0595 00. . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Oil Filter Replacement 0596 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Oil Filter Assembly, Lines And Bracket Repair (HATZ) 0597 00. . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Saber Gauge And Oil Filler Cap Replacement 0598 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Saber Gauge Replacement (HATZ) 0599 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 20 -- AUXILIARY GENERATORAND ENGINE AND CONTROLS (APU) MAINTENANCE -- CONTINUED

Auxiliary Power Unit Chaincase Instruction Plate, Breather Assembly,Oil Fill Plug And Oil Drain Plug Replacement 0600 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Chaincase Instruction Plate, Breather Assembly,Oil Fill Plug And Oil Drain Plug Replacement (HATZ) 0601 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Crankcase Oil Fill Lines Replacement 0602 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Crankcase Oil Fill Lines Replacement (HATZ) 0603 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Crankcase Oil Drain Lines Repair 0604 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Crankcase Oil Drain Lines Repair (HATZ) 0605 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Crankcase Oil Drain Hose Replacement 0606 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Crankcase Oil Drain Hose Replacement (HATZ) 0607 00. . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Intake Air Cleaner Assembly Replacement 0608 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel Filters Replacement 0609 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel Filter Assembly Replacement 0610 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel Filter Assembly Replacement (HATZ) 0611 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel Filter Identification Plate Replacement 0612 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Fuel Lines And Fittings Replacement 0613 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel System Service 0614 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Upper And Lower Fuel Pumps Replacement (HATZ) 0615 00. . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel/Water Separator Replacement (HATZ 0616 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel System Lines And Fittings Replacement (HATZ) 0617 00. . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Muffler And Exhaust System Replacement 0618 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Exhaust Manifold Replacement (HATZ) 0619 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Ducting Replacement 0620 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Ducting Replacement (HATZ) 0621 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Duct Replacement 0622 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Duct Replacement (HATZ) 0623 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Shrouds Replacement 0624 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Heat Shields Replacement (HATZ) 0625 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Engine Lifting Bracket And Oil Filter SupportBracket Replacement (HATZ) 0626 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel Pump And Relay Box Mounting Bracket, Oil Drain LinesBracket And Wiring Harness Bracket Replacement (HATZ) 0627 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Hot Air Pipe Replacement (HATZ) 0628 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Air Intake Adapter And Glow Plug Replacement (HATZ) 062900. . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fan Screen Replacement (HATZ) 0630 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Oil Pressure Transmitter Replacement 0631 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Oil Pressure Transmitter And Low Oil Pressure Switch Replacement (HATZ) 0632 00Auxiliary Power Unit High Air Temperature Switch Replacement (HATZ) 0633 00. . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Generator Replacement 0634 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Generator Replacement (HATZ) 0635 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Generator Mounting Studs Replacement 0636 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Generator Mounting Studs Replacement (HATZ) 0637 00. . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Diode And Mounting Plate Replacement 0638 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Diode And Mounting Plate Replacement (HATZ) 0639 00. . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Relay And Mounting Bracket Replacement 0640 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Relay And Mounting Bracket Replacement (HATZ) 0641 00. . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Wiring Harness 3W704 Replacement 0642 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Wiring Harness 3W704 Replacement (HATZ) 0643 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 3W705 Replacement 0644 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 3W705 Replacement (HATZ) 0645 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 3W706 Replacement 0646 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 3W706 Replacement (HATZ) 0647 00. . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 20 -- AUXILIARY GENERATORAND ENGINE AND CONTROLS (APU) MAINTENANCE -- CONTINUED

Auxiliary Power Unit Wiring Harness 3W711 Replacement 0648 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Wiring Harness 3W711 Replacement (HATZ) 0649 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 3W727 Replacement 0650 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 3W727 Replacement (HATZ) 0651 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 3W728 Replacement 0652 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 3W728 Replacement (HATZ) 0653 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Wiring Harness 3W730 Replacement (HATZ) 0654 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 11671380--1 Replacement 0655 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 11671380--1 Replacement (HATZ) 0656 00. . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 11671380--2 Replacement 0657 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 3W732 Replacement (HATZ) 0658 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 3W733 Replacement (HATZ) 0659 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Thermostatic Switch Replacement (HATZ) 0660 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Lead Assembly 336--0706 Replacement (HATZ) 0661 00. . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Relay Box Assembly Replacement (HATZ) 0662 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Hourmeter And Bracket Replacement (HATZ) 0663 00. . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Preheat Solenoid Replacement (HATZ) 0664 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Fuel Shut--Down Solenoid, Bracket And FuelStop Absorber Replacement (HATZ) 0665 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit Vaneaxial Fan, Screens And Bracket Replacement (HATZ) 0666 00. . . . . . . . . . . . . . .

CHAPTER 21 -- SPECIAL PURPOSE KITS MAINTENANCEDeep Water Fording Kit 0667 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bilge Pump Bracket And Inlet Flange Replacement 0668 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Smoke Generating System Fuel Tube Assemblies Replacement 0669 00. . . . . . . . . . . . . . . . . . . . .Exhaust Smoke Generating System Fuel Shutoff Valve, SolenoidValve And Related Parts Replacement 0670 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Smoke Grenade Launcher Arming Switch Box And Lamp assembly Repair 0671 00. . . . . . . . . . . . . . . . . . . .Smoke Grenade Launcher Bracket Replacement 0672 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Smoke Grenade Launcher Wiring Harness 1W112 Replacement 0673 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Smoke Grenade Launcher Wiring Harness 4W108 Replacement 0674 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remote Terminal Unit Replacement 0675 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 2W505 Replacement 0676 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 3W501 Replacement 0677 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W502 Replacement 0678 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W503 Replacement 0679 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W504 Replacement 0680 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W506 Replacement 0681 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W507 Replacement 0682 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W508 Replacement 0683 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Control Valve Manifold Assembly Switch, Transducers And AssociatedParts Replacement 0684 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Winch And Spade Assembly Transducers And Associated Parts Replacement 0685 00. . . . . . . . . . . .Boom Shut Off Valve Transducers And Associated Parts Replacement 0686 00. . . . . . . . . . . . . . . . . . . . . . .Hoist Winch Transducers And Associated Parts Replacement 0687 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main and Hoist Winch Directional Control Valve AssemblyTransducers And Associated Parts Replacement 0688 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filter Valve Manifold Transducers And Associated Parts Replacement 0689 00. . . . . . . . . . . . . . . . . . . . . . . .Main Hydraulic Pumps Switch, Transducers And Associated Parts Replacement 0690 00. . . . . . . . . . . . . . .Left And Right Side Boom Limit Valve Transducer, Switches And Associated Parts Replacement 0691 00.Transducer Calibration 0692 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 22 -- WELDING, METALIZING, METAL HEATING AND PLATINGEQUIPMENT MAINTENANCE

Acetylene Hose Adapter And Related Parts Equipment 0693 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 23 -- GAUGES (NONELECTRICAL)Mechanical Speedometer, Shaft Assembly, Gear Assembly,Housing And Related Parts Replacement 0694 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical Tachometer, Shaft Assembly, Pulse Tachometer, Angle Adapter,Drive Adapter And Related Parts Replacement 0695 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Fuel Pump Adapter Plate Replacement 0696 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 24 -- FIRE FIGHTING EQUIPMENT COMPONENTS MAINTENANCEFixed Fire Fighting Equipment -- Rear Half Replacement 0697 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixed Fire Fighting Equipment -- Front Half Replacement 0698 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixed Fire Extinguisher Actuator Cable Assembly Repair 0699 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixed Fire Extinguisher Valve Assembly And Related Parts Replacement 0700 00. . . . . . . . . . . . . . . . . . . . .Fixed Fire Extinguisher Manual Interlock System Components Replacement 0701 00. . . . . . . . . . . . . . . . . .Fixed Fire Extinguisher Pulley release Mechanism Replacement 0702 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixed Fire Extinguisher Cylinder And Lines Replacement 0703 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixed Fire Extinguisher Cylinder Mounting Brackets And Supports Replacement 0704 00. . . . . . . . . . . . . . .Fixed Fire Extinguisher Cylinder Cap Retaining Assemblies Repair 0705 00. . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 25 -- CHEMICAL, BIOLOGICAL AND RADIOLOGICAL (CBR) EQUIPMENT MAINTENANCEM2A2 Gas Particulate Filter Unit (GPFU), Hose Assemblies, Frame Assemblies,Brackets, Lead Assembly 4W303 And Associated Hardware Replacement 0706 00. . . . . . . . . . . . . . . . . . . .Air Purifier Control Unit Enclosure Assembly And Bracket Repair 0707 00. . . . . . . . . . . . . . . . . . . . . . . . . . . .M3 Air Heater Repair 0708 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W305 Replacement 0709 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W306 Replacement 0710 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Harness 4W307 Replacement 0711 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 26 -- PREPARATION FOR STORAGE OR SHIPMENTGeneral 0712 00--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Definition Of Administrative Storage 0712 00--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Administrative Storage 0712 00--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Care Of Equipment In Administrative Storage 0712 00--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Receipt For Storage 0712 00--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotation 0712 00--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal From Administrative Storage 0712 00--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing Equipment In Administrative Storage 0712 00--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparation For Storage And Shipment 0712 00--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shipment 0712 00--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 27 -- SUPPORTING INFORMATIONReferences 0713 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction For Maintenance Allocation Chart (MAC) 0714 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Allocation Chart 0715 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Expendable And Durable Items List 0716 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tool Identification List 0717 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mandatory Replacement Parts List 0718 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manufactured Items List 0719 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque Limits 0720 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alphabetical Index INDEX--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Schematics FP--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Schematics FP--23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM 9--2350--292--20--1

xviii

HOW TO USE THIS MANUAL

This manual was designed to provide you with the information you will need to maintain the M88A2 recovery vehicle.

The information contained in this manual is presented in chapters and work packages. Each chapter is divided into workpackages to cover the subject for vehicle system(s) or components. Where references are made to tables, figures, andwork packages, refer to those portions of the text.

To find information relating to a specific component or system:

Determine the specific name or function of the component/system.Find the name or function in the Index Listing, located in the back of this manual.Refer to appropriate work package(s) called out in the Index Listing.

To find information pertaining to a broader range of information (such as vehicle troubleshooting, preventive maitenancecomponent repair, and component descriptions):

Identify the desired topic.Find the general topic in the Table of Contents, located in the front of this manual.Refer to appropriate work package(s) called out in the Table of Contents.

MAINTENANCE

Throughout this manual you will frequently see “notify direct support maintenance”. When you are instructed tonotify direct support maintenance, do exactly that; they have the tools and training to efficiently and correctly per-form the next level of maintenance.

Maintenance procedures are to be performed in the sequence shown in the text and illustrations. Step 1 must be per-formed before step 2 and so on.

Equipment illustrations use numbers to identify parts of the system/components.

Throughout this manual the words WARNING, CAUTION, and NOTE will appear. There is a reason for every one ofthem.

WARNING

A warning is used to alert the user to hazardous operating and maintenance procedures,practices, conditions, statements, etc. that may result in injury to or DEATH or personnelif not strictly observed.

CAUTION

A caution is used to alert the user of hazardous operating and maintenance procedures,practices, conditions, statement, etc. that may result in damage to or destruction of equip-ment or of mission effectiveness if not observed.

NOTEA note is used to inform the user of essential information which is of speical interest orimportance or will aid the user in performing a job.

END OF TASK

TM 9--2350--292--20--1

0001 00--1

GENERAL INFORMATION 0001 00THIS WORK PACKAGE COVERS:

General information

SCOPE

Type of manual: Unit Maintenance.

Model number and equipment name: M88A2, Recovery Vehicle, Heavy.

Purpose of equipment: To provide for battlefield recovery (hoist/winch/tow) of vehicles up to and including the M1series tank.

MAINTENANCE FORMS, RECORDS AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DAPAM 738--750, The Army Maintenance Management System (TAMMS) as contained in the Maintenance Manage-ment Update.

Accidents involving injury to personnel or damage to materiel will be reported on DA Form 285 (Accident Reporting)in accordance with AR 385--40.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS

If your M88A2 HRV needs improvement, let us know. Send us an Equipment Improvement Recommendation(EIR). You, the user, are the only one who can tell us what you don’t like about our equipment. Let us know whyyou don’t like the design or performance. Put it on a SF 368 (Product Quality Deficiency Report). Mail it to the ad-dress specified in DA PAM 738--750.

HAND RECEIPT (HR) MANUALS

This manual has a companion document with a TM number followed by “--HR” (which stands for Hand Receipt).TM 9--2350--292--10--HR consists of preprinted hand receipts that list end item related equipment (i.e., COEI, BII,and AAL) that must be accounted for. As an aid to property accountability, additional HR manuals may be requisi-tioned through normal publication channels.

CORROSION PREVENTION AND CONTROL

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosionproblem with the HRV be reported so that improvements can be made to prevent the problem in the future. Whilecorrosion is typically associated with rusting of metals, it can also include deterioration of other materials such asrubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion prob-lem. If a corrosion problem is identified, it can be reported using SF 368, (Product Quality Deficiency Report). Useof keywords such as “corrosion,” “rust,” “deterioration,” or “cracking” will ensure that the information is identified asa CPC problem. SF 368 should be submitted to the address specified in DA PAM 738--750.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Refer to TM 750--244--6 for procedures on how to destroy the M88A2 HRV.

Below are some general guidelines to follow in destruction of equipment to prevent enemy use.

Destruction of the vehicle and equipment, when subject to capture or abandonment in a combat zone, will be un-dertaken only when such action is necessary in accordance with orders of, or policy established by, the Army com-mander.

In general, destruction of essential parts, followed by burning, will usually be sufficient to render the vehicle andequipment useless. Time is usually critical.

TM 9--2350--292--20--1

0001 00--2

GENERAL INFORMATION -- CONTINUED 0001 00

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE -- CONTINUED

Materiel must be damaged so that it cannot be restored to usable condition by either repair or cannibalization. Iflack of time or personnel prevents destruction of all parts, give priority to destruction of parts hardest to replace. Itis important that the same parts be destroyed on all vehicles to prevent construction of one complete vehicle fromseveral damaged ones.

The procedure outlined below requires the use of demolition materials and explosives which normally may not beauthorized items of issue to the using organization. The issue of these and related materials and conditions underwhich destruction will be effected, are command decisions in each case, according to the tactical situation.

Varying degrees of damage to the armament and other equipment may be expected during destruction of the ve-hicle as outlined below:

1. Remove and empty portable fire extinguishers and discharge the fixed fire extinguisher system.

2. Smash all vital elements such as auxiliary power unit, batteries, switches, instruments, hydraulic valves, cou-pling devices, mechanical transmission, hydraulic pumps and all accessible engine and transmission compo-nents. Slash hydraulic lines, electrical cables and harnesses.

3. Drain fuel and hydraulic oil tanks or puncture them as near the bottom as possible.

4. For the engine compartment, transmission, tracks, winches and boom, prepare eleven, 2--pound demolitioncharges. Use 1--pound TNT blocks or equivalent together with the necessary detonating cord to make up therequired charges. Place the required charges as follows:

D Set the first charge on the accessory drive housing at the forward end of the engine.

D Set the second and third charges on the engine, one on the left side and one on the rightside.

D Set the fourth charge between the engine and transmission.

D Set the fifth and sixth charges on the track drive sprockets, one on the left side and one onthe right side.

D Set the seventh charge on the main winch motor.

D Set the eighth and ninth charges on the hoisting boom at the boom crankarms, one on the leftside and one on the right side.

D Set the tenth and eleventh charges on the hoisting boom stayline crankarms, one on the leftside and one on the right side.

Connect all eleven charges for simultaneous detonation with detonating cord.

5. Provide for dual priming to minimize the possibility of a misfire. For complete details on the use of demolitionmaterials and methods of priming and detonating demolition charges, refer to FM 5--250. Training and carefulplanning are essential. The danger area is estimated to be 500 yards; elapsed time is approximately 10 min-utes.

PREPARATION FOR STORAGE OR SHIPMENT

Refer to WP 0712 00 for the requirements for Administrative Storage and requirements for vehicle shipment.

TM 9--2350--292--20--1

0001 00--3


WARRANTY INFORMATION

Refer to TB 9--2350--292--15 for warranty information pertaining to the M88A2 HRV.

NOMENCLATURE CROSS--REFERENCE LIST

Nomenclature in this manual was chosen in accordance with the terms used for provisioning as they appear in theRepair Parts and Special Tools List (RPSTL) and Maintenance Allocation Chart (MAC) for unit maintenance.

A few tools and components are, however, referred to by names more common than those in the RPSTL. In manycases the more common name is a shorter name for the same component.

OFFICIAL PROVISIONING NOMENCLATURE MORE COMMON NAME

Cable assembly Wiring harness or lead assemblyGauge rod Dipstick, bayonet gauge, saber gaugeSafety wire LockwireSocket head screw key Hex keySolid rubber wheel RoadwheelWire rope CableEngine analyzer set STE--ICE--RVehicle cargo tie--down Track binderKey, woodruff key, machine key Key

LIST OF ABBREVIATIONSAAL Additional Authorized ListAOAP Army Oil Analysis ProgramATE Automatic Test EquipmentBDAR Battlefield Damage Assessment and RepairBII Basic Issue Item_C Degree CentigradeCAGEC Contract and Government Entity CodeCAM Chemical Agent MonitorCAR Corrective Action ReportCARC Chemical Agent Resistant CoatingCCW CounterclockwiseCM CentimetersCOEI Component Of End ItemCPC Corrosion Prevention and ControlCTA Common Table of AllowancesCW ClockwiseDC Direct CurrentDCA Diagnostic Connector AssemblyDMWR Depot Maintenance Work OrderDOD Department of DefenseDS Direct SupportEIR Equipment Improvement Recommendation_F Degree FahrenheitFMC Fully Mission CapableFOV Family of VehiclesFRH Fire Resistant, Rust Inhibited Hydraulic FluidFWD ForwardGND GroundGS General SupportHRV Heavy Recovery VehicleKG KilogramKPH Kilometer Per Hour

TM 9--2350--292--20--1

0001 00--4


LIST OF ABBREVIATIONS -- CONTINUEDL LiterLRU Line Replaceable UnitM MeterMM MilimeterMAC Maintenance Allocation ChartMAX MaximumMIN MinimumMOS Military Occupational SpecialtiesMPH Miles Per HourMTOE Modified Table of Organization and EquipmentN NeutralNBC Nuclear, Biological, ChemicalNSN National Stock NumberPMCS Preventative Maintenance Checks and ServicesPSI Pounds Per Square InchPWR PowerQA Quality AssuranceQDR Quality Deficiency ReportR ReverseRPM Revolutions Per MinuteRPSTL Repair Parts and Special Tools ListSPORT Soldier’s Portable On--system Repair ToolSTE Special Test EquipmentSTE/ICE--R Simplified Test Equipment for Internal Combustion

Engines ReprogrammableTB Technical BulletinTM Technical ManualTAMMS The Army Maintenance Management SystemTMDE Test, Measurement, Diagnostic EquipmentTOE Tables of EquipmentVIS Vehicle Intercommunications SystemWP Work Package

QUALITY ASSURANCE (QA)

No particular quality assurance manual pertains specifically to the M88A2 HRV.

Defective material received through the supply system should be reported on Quality Deficiency Report (QDR)SF 368. Instructions for preparing QDR’s are provided in AR 702--7, Reporting of Quality Deficiency Data. QDR’sshould be mailed directly to:

CommanderU.S. Army Tank--automotive and Armaments CommandATTN: AMSTA--QRTWarren, MI 48397--5000

A reply will be furnished directly to you.

TM 9--2350--292--20--1

0001 00--5


COMMON TOOLS AND EQUIPMENT

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE),CTA 50--970; or CTA 8--100, as applicable to your unit.

The tool kit (box) assigned to the mechanic (on a 1--per--mechanic--by MOS basis) shall be identified in the individu-al maintenance paragraphs by nomenclature, item number and work package. No tool in the kit shall be furtheridentified. Other tools required for performance of tall tasks for the maintenance levels covered in the manual shallbe identified in the setup and shall be referenced to the Tool identification List, WP 0717 00. “Other tools” includestools which are part of the components of shop sets authorized to section/teams; tools authorized by RPSTL andCTA 50--970; special and fabricated tools; and items of TMDE.

SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

Special tools and equipment necessary to perform the maintenance described in this manual are listed in WP0715 00 for information only. Special tools and equipment are listed in TM 9--2350--292--24P, which is the authorityfor requisitioning replacements. Fabricated tools are identified in the initial setup; manufacturing instructions forfabricated tools are found in WP 0719 00

TOOLS, TMDE, AND SUPPORT EQUIPMENT

Refer to Maintenance Allocation Chart (MAC), WP 0715 00 and Repair Parts and Special Tools List (RPSTL)TM 9--2350--292--24P for tools. Fabricated tools are located in WP 0719 00.

REPAIR PARTS

Repair parts are listed and illustrated in the repair parts and special tools list covering unit maintenance (TM9--2350--292--24P). All mandatory replacement parts identified in the initial setup are listed in WP 0718 00 of thismanual.

Gaskets, packings, preformed packings, seals, lockwashers, locknuts, self--locking nuts, cotter pins and spring pinsmust be replaced. Bushings must be replaced only if removed.

Springs must be replaced if broken, kinked, cracked or do not conform to standards specified in the repair data.

COPYRIGHT CREDIT LINE

COPYRIGHT E 1998 BY UNITED DEFENSE, L.P. ALL RIGHTS RESERVED UNDER THE COPYRIGHT LAWS.

THIS MATERIAL MAY BE REPRODUCED FOR U.S. GOVERNMENT PURPOSES ONLY, PURSUANT TO THE COPYRIGHT LICENSE UNDERTHE CLAUSE AT (DFARS 52.227--7013) 1994.

END OF TASK

0001 00--5/6 blank

TM 9--2350--292--20--1

CHAPTER 1

DESCRIPTION AND THEORY OF OPERATION

TM 9--2350--292--20--1

0005 00--1

THEORY OF OPERATION 0005 00THIS WORK PACKAGE COVERS:

Powerpack, Tracks and Suspension, Fixed Fire Extinguisher System, Hydraulic System, Winch and SpadeAssemblies, Auxiliary Power Unit, Gas/Particulate Filter Unit (GPFU), M2A2 Air Purifier with M3 Heaters, SmokeGrenade Launcher System, M239, Exhaust Smoke Generating System, Deep Water Fording Kit, and ElectricalSystem

POWERPACK

Consists of the engine, cross--drive transmission and right and left output reduction gear drive. The powerpack isremoved from the vehicle as one complete unit.

The front of the engine is referred to as the damper--end or front, the rear of the engine is referred to as the fly-wheel--end or rear. As viewed from the front or damper--end toward the rear or flywheel--end, the side to the right iscalled the right--side and the side to the left is called the left--side. Viewing the engine from the front, the right bankof cylinders is numbered 1R through 6R and the left bank of cylinders is numbered 1L through 6L.

6R 5R 4R 3R 2R 1R

MAIN ENGINEENGINE REAR

(FLYWHEEL END)ENGINE FRONT(DAMPER END)

6L 5L 4L 3L 2L 1L

VEHICLELEFT

VEHICLEFRONT

VEHICLEREAR

CROSS--DRIVETRANSMISSION

(CENTERSECTION)

VEHICLERIGHT

LEFTOUTPUT

REDUCTIONGEAR

RIGHTOUTPUT

REDUCTIONGEAR

LEFT DRIVESPROCKETS AND HUB

RIGHT DRIVESPROCKETS AND HUB

LEFTDRIVECOUPLING

RIGHTDRIVECOUPLING

ENGINERIGHTBANK

ENGINELEFTBANK

ENGINE

The Teledyne Vehicle Systems model AVDS--1790--8CR engine is a 12--cylinder, 90--degree, V--type, 4--cycle, air--cooled, turbosupercharged diesel engine. The cylinder assemblies are individually replaceable units with overheadvalves and valve rocker assemblies in the head. The cylinders are arranged in two banks of six cylinders each.Each bank of cylinders has an overhead camshaft arrangement to actuate the valves of each cylinder.

The engine’s fuel injection system utilizes a fuel metering pump which supplies metered fuel to individual cylindersthrough fuel injector nozzles. The engine fuel pump assembly, located at the front of the engine, delivers fuel to themetering pump. A turbosupercharger is located on each side of the engine at the rear. The exhaust--gas driventurbosupercharger increases the air flow pressure entering the air intake manifolds.

TM 9--2350--292--20--1

0005 00--2

THEORY OF OPERATION -- CONTINUED 0005 00

ENGINE -- CONTINUED

The engine’s fuel system primary and fuel/water separator--type secondary fuel filters have top--mounted bleedervalves to assist in the removal of air from the fuel system. Water is removed automatically by a constant bleed ori-fice in the primary fuel filter and an automatic water drain in the fuel/water separator filter.

The forced--feed engine lubrication system consists of three circuits: the scavenge circuit, the main or pressurecircuit and the piston cooling circuit. Each circuit is operated independently by one oil pump which consists of fourseparate pump sections.

The engine crankcase is vented by the crankcase breather system which exhausts through the crankcase breathertube at the left turbosupercharger exhaust outlet.

The engine is equipped with two intake manifold heaters which are installed in the air intake system between theintake manifold elbows and the turbosuperchargers. The heaters, when operated, preheat the air entering the cyl-inders to facilitate cold--weather starting and cold--weather idle operation.

The engine is equipped with a 650--amp, 28--V dc generator and a 24 V dc solenoid--operated starter.

1 Smoke generator manual fuelshutoff valve

2 Front crankcase breather tube3 Fire extinguisher tube4 Speed governing solenoid5 Oil filter bypass valve6 Manual fuel shutoff7 Fuel pump assembly8 Primary fuel filter

9 Oil pressure warning switch10 Oil pressure gage transmitter11 Oil pressure regulator valve12 Fuel check valve (Fuel back-

flow valve)13 Damper housing oil drain valve14 Power takeoff coupling15 Cylinder head oil drain tube16 Manifold heater fuel filter

17 Manifold heater fuel solenoidvalve

18 Oil cooler bypass valve

19 Oil sampling valve cock

20 Engine oil cooler thermostaticbypass valve

21 Oil filter

22 Fuel/water separator

1 2 3 4 5 6 7

8

9

20

10

11

12131415

17

16

18

19

21

22

TM 9--2350--292--20--1

0005 00--3


ENGINE -- CONTINUED

34

35

23 24 25 26

27

28

29

3031

3233

23 Exhaust manifold pipe 30 Fuel/water automatic drain24 Manifold heater fuel return solenoid control25 Smoke generator fuel solenoid 31 Starter low voltage module26 Left bank turbosupercharger 32 Manifold heater27 Engine oil cooler 33 Engine starter28 Transmission oil cooler 34 Oil filler tube29 Air intake manifold 35 Flywheel

36

3837

39

41

40

42

4345

51

51

44

46

47

48

49

50

36 Smoke generator system fuel supply tube37 Engine oil level check38 Front engine cooling fan39 Rear engine cooling fan40 Transmission oil cooler thermostatic bypass

valve41 Right bank turbosupercharger42 Transmission oil cooler43 Engine generator

44 Engine oil cooler45 Air intake manifold46 Tachometer drive adapter47 Oil pan48 Crankcase49 Time totalizing meter50 Front lifting eyes51 Hydraulic oil coolers

TM 9--2350--292--20--1

0005 00--4


FUEL SYSTEM

Three fuel tanks supply fuel to the engine, auxiliary power unit and the refuel system. Two tanks are adjacent to theengine, one on either side and one forward of the bulkhead in the hydraulic compartment.

A system of four manually operated control valves (1) maintains fuel flow through the check valve (2) and directsfuel to the engine and refueling systems. These valves are also used to drain the fuel tanks.

The fuel from the vehicle fuel tanks is supplied at a minimum pressure of 5 psi to the primary fuel filter (3), which ismounted on the engine right front. Fuel flows through the main fuel check valve (fuel backflow valve) (4) to the en-gine fuel pump (5) mounted on the front center of the engine. This is an engine--driven, gear--type pump; it boostsfuel pressure to the fuel metering pump (6). A relief valve is incorporated in the pump as a pressure limiting safetyvalve.

Fuel from the engine fuel pump (5) is filtered through the fuel/water separator filter (7) and passes into the fuel me-tering pump (6), located in the engine V between the cooling fans. The metering pump (6) delivers metered quanti-ties of fuel under high pressure to each cylinder. An integral governor, of the mechanical--centrifugal type, is usedto control fuel delivery as a function of engine speed. Engine shutoff is accomplished by a normally open solenoidcontrol unit in the metering pump (6).

Twelve stainless steel fuel lines (8) carry fuel under high pressure from the fuel metering pump (6) to the twelve fuelinjector nozzles (9) on the left and right banks of the engine. The nozzles (9) inject a fine spray of metered fuel un-der pressure into each cylinder. Excess fuel is carried from the nozzles (9) through return tubes (10) and hoses(11) on each cylinder bank to the fuel return system.

The engine fuel shutoff switch on the master control panel actuates the circuit to close the solenoid in the fuel injec-tor pump (6). Closing the solenoid cuts off fuel from the metering pump (6) and stops the engine. The engine isequipped with a manual fuel shutoff control (12) to stop the engine if the electric fuel shutoff should fail. A bleederpressure--relief valve (13) in the pump outlet maintains a constant fuel pressure by allowing any accumulated airand excess fuel to return to the fuel tanks through the engine and fuel tank return tubes (10), check valve (14), re-turn hoses (11) and control valves (1). Excess fuel is used to lubricate and cool the fuel metering pump (6). Thecheck valve (14) prevents a back flow of fuel into the metering pump (6) from the fuel return tubes (10) and hoses(11) and prevents continued engine operation after the fuel shutoff valve is closed.

TM 9--2350--292--20--1

0005 00--5


FUEL SYSTEM -- CONTINUED

FORWARD

1

1

212

11 911 991111 91111 93 9

8 88

8 88

104

5

7

118 8

8 88

10

8

1199 11 119 119 9 11 9

1413

6

11

TM 9--2350--292--20--1

0005 00--6


MANIFOLD AIR INDUCTION HEATER SYSTEM

The intake manifold tubes (1) equipped with electrical intake manifold heater ignition units (2) distribute heated su-percharged air into each bank of cylinders. These air heaters (3) assist engine starting during cold weather.

Operation of the heater switch energizes the manifold heater fuel inlet solenoid valve (4) to allow fuel flow to theheater nozzles (5). The heater switch also energizes the ignition units (2) to create an electrical spark in the man-ifold tubes (1), thereby igniting the sprayed fuel.

A leakoff line (6) prevents nozzle fouling and is routed into the fuel injector fuel return line. The fuel is burned in theintake manifold tubes (1) by the ignition of the heater spark plugs (7) which flame heats the incoming air. Thisflame--heated air and the products of combustion flow directly into the cylinders.

The check valve (fuel backflow valve) (8) ensures the necessary fuel pressure to operate the flame heater nozzles(5). An inlet solenoid valve (4) and fuel return solenoid valve (9) close the flame heater fuel lines (10) when theflame heater switch is off.

The manifold heater fuel return solenoid valve (9) is located at the rear of the engine. When the valves (4 and 9)become energized, the ignition units (2) and heater spark plugs (7) act as a check valve to prevent fuel returningfrom the injector pump and nozzles from entering the air induction heater system.

8

FUEL INLETFROM PURGE

PUMP

FUEL INLETFROM PRIMARYFUEL FILTER

ELECTRICALCONNECTOR

FUEL RETURN FROMFUEL INJECTOR PUMP

FUEL RETURNFROM FUELINJECTOR NOZZLES

FUEL RETURNTO VEHICLEFUEL TANK

6 9

6

5

37

5

1010

4

1

21

2 7

3

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